PROCESS FOR THE PREPARATION OF A SPHERICAL SUPPORT COMPRISING MgCl2 AND ALCOHOL

Abstract

The present disclosure relates to a process for preparing a MgCl2-alcohol adduct which comprises (a) forming a mixture of an MgCl2-alcohol adduct in molten form and a liquid which is immiscible with the adduct, (b) subjecting the mixture to a shear stress to obtain an emulsion, and (c) rapidly cooling the emulsion to solidify the disperse phase and collecting the solid adduct particles, the process being characterized by the fact that step (b) is carried out in a device comprising a first outer and second inner cylindrical members that define an annulus between them, wherein at least one of the cylindrical members rotate with respect to the other.

Description

FIELD OF THE INVENTION[0001]The present disclosure relates to a process for preparing a support, in the form of spherical particles with narrow particle size distribution, which can be used in the preparation of olefin polymerization supported catalysts. In some embodiments, the present disclosure relates to a process for preparing the support, which involves forming an emulsion of a liquid molten adduct of magnesium dihalide and an alcohol with an immiscible liquid by feeding the liquids to a Couette type device generating a constant shear stress throughout the flow domain. This process produces support particles capable of generating catalysts that give polymers in higher yields and / or with improved morphology.BACKGROUND OF THE INVENTION[0002]The availability of catalysts able to produce polymers with optimal morphological properties is a fundamental requirement in any olefin polymerization technology. A polymer having a spherical regular form allows for increased bulk density and...

AI Technical Summary

Benefits of technology

This patent describes a process for making a type of chemical called MgCl2-alcohol adduct. The process involves melting the adduct and mixing it with a liquid that doesn't mix well with the adduct. Then, the mixture is subjected to a strong shear force to create a smooth emulsion. Finally, the emulsion is quickly cooled to solidify the adduct particles. The key finding is that the process is carried out using a device that generates a consistent shear stress across the entire flow of the mixture. This device consists of two cylinders that rotate with respect to each other. The technical effect of this process is that it allows for the creation of a stable and consistent adduct that can be used in various applications.

Problems solved by technology

Under these conditions it is difficult to obtain a narrow particle size distribution, because with the reduction of size the coalescence phenomena will increase.

However, this process is complicated and it would be advisable to find an easier way to produce catalyst precursors with narrow particle size distributions over a broad range of average particle size.

In cases of very low or high viscosity ratios it becomes several hundred times more difficult to break a drop by uniform rotational shear as described in U.S. Pat. No. 7,581,436, wherein the wide applicability limits the working examples to emulsions composed by crude oil and water, which have similar viscosities.

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